Graco 309457E - PRO Auto Xs Air Spray Gun, Electrostatic, for Waterborne Coatings Owner's Manual
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Instructions/Parts List
ELECTROSTATIC, FOR WATERBORNE COATINGS
PRO
™
Auto Xs
Air Spray Gun
Part No. 244591, Series A
100 psi (0.7 MPa, 7 bar) Maximum Air Inlet Pressure
100 psi (0.7 MPa, 7 bar) Maximum Working Fluid Pressure
For use when electrostatically spraying conductive, waterborne fluids that meet at least one of the following conditions for non-flammability:
• The fluid has a flash point above 140
°
F (60
°
C) and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
• The fluid does not sustain burning when tested per
ASTM Standard D4206 Sustained Burn Test.
Fluid hose must be ordered separately.
U.S. Patent Pending
309457E
TI1557A
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for Table of Contents.
Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2002, Graco Inc. is registered to I.S. EN ISO 9001
2
Table of Contents
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning Symbol . . . . . . . . . . . . . . . . . . . . . . . . . 3
Caution Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
How the Electrostatic Air Spray Gun Works . . . . 7
Spraying Waterborne Fluids Electrostatically . . . 7
Gun Features and Options . . . . . . . . . . . . . . . . . 7
Operating the Spray Function . . . . . . . . . . . . . . . 8
Operating the Electrostatics . . . . . . . . . . . . . . . . 8
Changing the kV Setting . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Install the System . . . . . . . . . . . . . . . . . . . . . . . 10
Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ventilate the Spray Booth . . . . . . . . . . . . . . . . . 11
Install the Air Line Accessories . . . . . . . . . . . . . 13
Install the Gun and Mounting Bracket . . . . . . . . 13
Connect the Air Line . . . . . . . . . . . . . . . . . . . . . 14
Manifold Connections . . . . . . . . . . . . . . . . . . . . 15
Connect the Waterborne Fluid Hose . . . . . . . . . 16
Optional Fiber Optic Cable Connection . . . . . . . 19
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check Electrical Grounding . . . . . . . . . . . . . . . . 21
Install the Fabric Cover . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fluid Voltage Discharge and Grounding Procedure
Pressure Relief Procedure . . . . . . . . . . . . . . . . 24
Operating Checklist . . . . . . . . . . . . . . . . . . . . . . 24
Select a Fluid Nozzle and Air Cap . . . . . . . . . . 25
Adjust the Spray Pattern . . . . . . . . . . . . . . . . . . 26
Adjust the Electrostatics . . . . . . . . . . . . . . . . . . 28
Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Triggering the Fluid Alone . . . . . . . . . . . . . . . . . 29
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Daily Care and Cleaning . . . . . . . . . . . . . . . . . . 30
Clean the Air Cap and Fluid Nozzle . . . . . . . . . 32
Check for Fluid Leakage . . . . . . . . . . . . . . . . . . 33
Electrical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Test Gun Resistance . . . . . . . . . . . . . . . . . . . . . 34
Test Power Supply Resistance . . . . . . . . . . . . . 35
Test Electrode Resistance . . . . . . . . . . . . . . . . . 36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Voltage Loss Troubleshooting . . . . . . . . . . . . . . 37
Spray Pattern Troubleshooting . . . . . . . . . . . . . 40
Gun Operation Troubleshooting . . . . . . . . . . . . . 41
Electrical Troubleshooting . . . . . . . . . . . . . . . . . 42
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Prepare the Gun for Service . . . . . . . . . . . . . . . 43
Remove the Gun from the Manifold . . . . . . . . . . 44
Install the Gun on the Manifold . . . . . . . . . . . . . 44
Air Cap/Nozzle Replacement . . . . . . . . . . . . . . 45
Electrode Replacement . . . . . . . . . . . . . . . . . . . 46
Fluid Packing Removal . . . . . . . . . . . . . . . . . . . 47
Packing Rod Repair . . . . . . . . . . . . . . . . . . . . . . 48
Piston Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Adjust the Actuator Arm . . . . . . . . . . . . . . . . . . 50
Barrel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 51
Barrel Installation . . . . . . . . . . . . . . . . . . . . . . . . 52
Power Supply Removal and Replacement . . . . 53
Turbine Alternator Removal and Replacement . 54
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Air Line Accessories . . . . . . . . . . . . . . . . . . . . . 59
Fluid Line Accessories . . . . . . . . . . . . . . . . . . . 59
Miscellaneous Accessories . . . . . . . . . . . . . . . . 60
Gun Accessories . . . . . . . . . . . . . . . . . . . . . . . . 61
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 64
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 64
309457E
Symbols
Symbols
Warning Symbol Caution Symbol
WARNING
This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.
CAUTION
This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.
309457E 3
4
Warning
WARNING
Electric Shock Hazard
Improper grounding, setup, or usage of an isolated waterborne system can cause a hazardous condition and result in electric shock or other serious injury.
• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all conductive objects in the spray area. See Grounding, page 20.
• The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.
• All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits personnel from making contact with the high voltage components before the system voltage is discharged.
• The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air supply anytime the isolation system enclosure is opened.
• The voltage isolation system must be interlocked with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone enters the spray area.
• The areas of the waterborne hose that are accessible to personnel must be covered by the conductive hose layer. The area of the hose that is not covered by the conductive hose layer must be inside the voltage isolation system enclosure.
• Only use the red-colored Graco grounded turbine air hose with this gun. Do not use the black or grey-colored air hoses.
• Install only one continuous Graco waterborne fluid hose between the isolated fluid supply and the spray gun. Do not splice hoses together.
•
Follow the Fluid Voltage Discharge and Grounding Procedure on page 23 when instructed
to discharge the voltage; before cleaning, flushing, or servicing the system; before approaching the front of the gun; and before opening the enclosure for the isolated fluid supply.
• Do not enter a high voltage or hazardous area until all high voltage equipment has been discharged.
• Do not come within 2 ft (0.61 m) of the gun nozzle during gun operation or until you follow the
Fluid Voltage Discharge and Grounding Procedure.
• Follow the warnings and instructions in the voltage system isolation system manual.
309457E
309457E
Warning
WARNING
Fire and Explosion Hazard
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and result in a fire or explosion.
• Electrostatic equipment must be used only by trained, qualified personnel who understand the requirements in this manual.
• Ground the equipment, all personnel in or close to the spray area, the object being sprayed,
and all other electrically conductive objects in the spray area. See Grounding, page 20.
• Provide fresh air ventilation to avoid buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Interlock the gun air supply to prevent operation of the power supply
unless ventilating fans are on. See Ventilate the Spray Booth on page 11.
• Do not flush with the gun electrostatics turned on.
• If there is any static sparking while using the equipment, stop spraying immediately. Identify and correct the problem.
• Eliminate all ignition sources such as pilot lights, cigarettes, and static arcs from plastic drop cloths. Do not plug in or unplug power cords or turn lights on or off in the spray area.
•
Check gun resistance daily. See Test Gun Resistance on page 34.
• Only use this equipment to spray non-flammable, waterborne fluids, as defined on the front cover of this manual.
• Only flush, purge, or clean the electrostatic waterborne spray system with non-flammable fluids, as defined on the front cover of this manual.
• Keep the spray area free of debris and rags. Do not store solvent and flammable fluids in the spray area.
• Use only non-sparking tools to clean residue from the booth and hangers.
Toxic Fluid Hazard
Hazardous fluids or toxic fumes can cause a serious injury or death if splashed in the eyes or on the skin, swallowed, or inhaled.
• Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
• Store hazardous fluid in an approved container. Dispose of the hazardous fluid according to all local, state, and national guidelines.
• Wear appropriate protective clothing, gloves, eyewear, and respirator.
5
6
Warning
WARNING
Equipment Misuse Hazard
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result in a serious injury.
• This equipment is for professional use only.
• Read all manuals, tags, and labels before operating the equipment.
• Use the equipment only for its intended purpose. If you are uncertain, call your Graco distributor.
• Do not alter or modify equipment. Use only genuine Graco parts and accessories.
• Do not operate the power supply above 60 kV. Use only Graco Part No. 244542 Power Supply with this gun.
• Check the equipment daily. Repair or replace worn or damaged parts immediately.
• Do not exceed the maximum working pressure of the lowest rated system component. Maximum working air and fluid pressure of this equipment is 100 psi (0.7 MPa, 7.0 bar).
• Use fluids and solvents that are compatible with the equipment wetted parts. See the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
• Route the hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose Graco hoses to temperatures above 180
°
F (82
°
C) or below -40
°
F (-40
°
C).
• Wear hearing protection when operating this equipment.
• Comply with all applicable local, state, and national fire, electrical, and other safety regulations.
Pressurized Equipment Hazard
Spray from the gun, hose leaks, or ruptured components can splash fluid in the eyes or on the skin and cause serious injury.
• Do not point the spray gun at anyone or at any part of the body.
• Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
•
Follow the Pressure Relief Procedure, page 24, when you stop spraying and before cleaning,
checking, or repairing equipment.
• Check hoses and couplings daily. Replace worn, damaged, or loose parts immediately.
• Tighten all fluid connections before each use.
309457E
Introduction
Introduction
How the Electrostatic Air
Spray Gun Works
The automatic electrostatic air spray gun operates very similar to a traditional air spray gun. The atomization and fan air are emitted from the air cap. The atomization air breaks up the fluid stream and controls the droplet size. The fan air controls the shape and width of the spray pattern. The fan and atomization air can be adjusted independently.
Spraying Waterborne Fluids
Electrostatically
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.
This electrostatic air spray gun is designed to spray only waterborne fluids with a flash point above 140
°
F (60
°
C) and a maximum organic solvent concentration of 20%, by weight, per ASTM Standard D93. Also, the fluid must not sustain burning when tested per ASTM Standard
D4206 Sustained Burn Test.
When connected to a voltage isolation system, all of the fluid in the spray gun, fluid hose, and isolated fluid supply is charged to high voltage, which means that the system has more electrical energy than a solvent-based system. Therefore, only non-flammable fluids (as defined on the front cover of this manual) can be sprayed with the system or be used to clean, flush, or purge the system.
Precautions must be taken when using electrostatic waterborne equipment to avoid potential shock hazards.
When the spray gun charges the isolated fluid to high voltage, it is similar to charging a capacitor or a battery.
The system will store some of the energy while spraying and retain some of that energy after the spray gun is shut off. It is not safe to touch the front end of the gun until the stored energy is discharged. The amount of time it takes to discharge the energy depends on the
system design. Follow the Fluid Voltage Discharge
and Grounding Procedure on page 23 before
approaching the front of the gun.
A safe, well designed voltage isolation system should have the following features:
• All components of the isolation system that are charged to high voltage must be contained within an enclosure that prohibits persons from making contact with the high voltage components before the system voltage is discharged.
• The voltage isolation system must be interlocked with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone opens the enclosure or enters the spray area.
• A bleed resistor to drain off the system voltage when the spray gun is not in use.
• The system should not have any severe arcing occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.
Gun Features and Options
• The gun is designed for use with a reciprocator, and can be mounted directly on a 1/2 in. (13 mm) rod.
With additional brackets, the gun can be mounted for robotic applications.
• Gun functions are activated from a separate controller that sends the appropriate signal to the actuating solenoids.
309457E 7
8
Introduction
• The optional fiber optic readout system can be installed to monitor the gun’s spraying voltage. A fiber optic cable connected to the gun manifold carries the signal from the gun to a remote display module. Part No. 224117 Display Module displays the gun’s spraying voltage and current. Battery-operated Display Module 189762 displays the gun’s spraying voltage only.
Operating the Electrostatics
To operate the electrostatics, apply air pressure to the gun manifold’s turbine air fitting (TA) through a Graco grounded air hose. The air enters the manifold and is directed to the inlet of the power supply turbine. The air spins the turbine, which then provides electrical power to the internal high voltage power supply. The fluid is charged by the spray gun electrode. The charged fluid is attracted to the nearest grounded object, wrapping around and evenly coating all surfaces.
The turbine air is exhausted into the shroud and out the back of the manifold through the exhaust fitting (EXH).
The exhaust air helps keep contaminants out and helps keep the gun clean.
WARNING
Electric Shock Hazard
To reduce the risk of electric shock, do not use the Graco ES Display Module readings to determine if your system is discharged.
The display modules will only display the system voltage while the gun’s power supply is operating. Follow
the Fluid Voltage Discharge and Grounding Pro-
cedure on page 23 to ensure the system is dis-
charged.
Operating the Spray
Function
Applying a minimum of 50 psi (0.35 MPa, 3.5 bar) air pressure to the gun manifold’s cylinder air fitting (CYL) will retract the gun piston, which opens the air valves and a short time later opens the fluid needle. This provides the proper air lead and lag when triggering the gun. A spring returns the piston when the cylinder air is shut off.
Changing the kV Setting
The gun’s full voltage setting is 60 kV. Three lower voltage settings are possible by actuating the KV1 and KV2 switches. Supply 50 psi (0.35 MPa, 3.5 bar) air pressure to the KV1 and KV2 ports. Turn the air on or off as
shown in Table 1 to set the desired voltage.
The solenoid valves used to activate the KV1 and KV2 switches must bleed the air out of the lines for the switches to draw back to the higher voltage setting.
Table 1: Low Voltage Adjustment
1
ON
ON
OFF
OFF
2
ON
OFF
ON
OFF kV
35
40
50
60
309457E
A C D
H
E
TI1557A
J
B
F
TA
CYL
A1
P1
TI1780A
TI1790A
Manifold Back View
Introduction
KV1
FO
KV2
A2
P2
EXH
G
Fig. 1. Gun Overview
Key
E
F
G
H
J
C
D
A
B
Air Cap
Fluid Nozzle
Retaining Ring
Shroud
Mounting Bracket
Manifold
Turbine
Power Supply
Electrode
309457E
A1
A2
Manifold Markings
Atomization Air Inlet Fitting
Fan Air Inlet Fitting
CYL Cylinder Air Inlet Fitting
EXH Shroud Exhaust Outlet Fitting
FO Fiber Optic Fitting (shipped unassembled)
KV1 kV Switch 1 Air Inlet
KV2 kV Switch 2 Air Inlet
P1
P2
TA
Fluid Supply Inlet Fitting
Not Used
Turbine Air Inlet Fitting
9
Installation
Installation
Install the System
WARNING
Fire, Explosion, and Electric Shock Hazard
Installing and servicing this equipment requires access to parts which may cause electric shock or other serious injury if work is not performed properly.
•Do not install or service this equipment unless you are trained and qualified.
•Be sure your installation complies with all
National, State and Local safety and fire codes, NFPA 33, NEC 504 and 516, and
OSHA standard 1910.107.
F IG . 2. shows a typical electrostatic air spray system,
and F IG . 3. shows possible system options. It is not an actual system design. For assistance in designing a system to suit your particular needs, contact your Graco distributor.
Basic Guidelines
When spraying waterborne fluids electrostatically:
• The gun must be connected to a voltage isolation system, which isolates the fluid supply from ground and allows voltage to be maintained at the tip of the gun.
• The gun must be connected to a voltage isolation system that will discharge the system voltage when the gun is not in use.
• All components of the isolation system that are charged to high voltage must be contained within a fence or enclosure that prohibits persons from making contact with the high voltage components before the system voltage is discharged.
• The gun turbine air supply must be interlocked with the isolation system to shut off the turbine air supply anytime the isolation system enclosure or safety fence is opened.
• The voltage isolation system must be interlocked with the spray area entrance to automatically discharge the voltage and ground the fluid whenever someone enters the spray area.
• The system should not have any severe arcing occurring when the isolation mechanism opens and closes. Severe arcing will shorten the life of the system components.
Graco Waterborne Fluid Hose
Use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun fluid inlet. See
Accessories on page 59 for available hoses. The hose
consists of an inner PTFE tube, a conductive layer covering the PTFE tube, and an outer cover.
If a hose failure occurs where high voltage arcs through the inner tube, voltage will be discharged to ground through the conductive hose layer. When properly installed, the conductive hose layer is grounded through its connection to the grounded enclosure.
10 309457E
Installation
Warning Signs
Mount warning signs in the spray area where they can easily be seen and read by all operators. An English
Warning Sign is provided with the gun.
Ventilate the Spray Booth
WARNING
Flammable or Toxic Vapor Hazard
Provide fresh air ventilation to avoid the buildup of flammable or toxic vapors when spraying, flushing, or cleaning the gun. Do not operate the gun unless ventilation fans are operating.
Electrically interlock the gun turbine air supply (B) with the ventilators to prevent gun operation without ventilating fans operating. Check and follow all National, State, and Local codes regarding air exhaust velocity requirements.
High velocity air exhaust will decrease the operating efficiency of the electrostatic system. The minimum allowable air exhaust velocity is 60 ft/minute (19 linear meters/minute).
IG . 3.
Q
R
N
P
J
K
L
M
U
V
S
T
W
G
H
E
F
C
D
A
B
X
Y
Air Hose Ground Wire
Graco Grounded Turbine Air Hose (TA)
Atomizing Air Hose, 3/8 in. (10 mm) OD (A1)
Fan Air Hose, 3/8 in. (10 mm) OD (A2)
Cylinder Air Hose, 5/32 in. (4 mm) OD (CYL)
Graco Waterborne Fluid Hose (P1)
To Isolated Fluid Supply System
Auto PRO Xs Air Spray Gun
Mounting Bracket for 1/2 in. (13 mm) rod
Solenoid Valve, requires quick exhaust port
Bleed-Type Master Air Valve
Air Pressure Regulator
True Earth Ground
24 Volt Power Supply
4-20 microampere Outputs
Full Feature ES Display Module kV Only ES Display Module (battery operated)
Fiber Optic Y Cable
Bulkhead
Fiber Optic Cable
Main Air Line kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV1 fitting if not used) kV Switch Air Hose, 5/32 in. (4 mm) OD (optional; plug KV2 fitting if not used)
309457E 11
Installation
L W
See * above
L
L
K P1
M
Non-Hazardous Area
N
E
G
Hazardous Area
F
J
TI1801A
Manifold Back View
Fig. 2. Typical Installation
P
NOTE:
** A maximum of two splices with a total of 108 ft (33 m) of cable can be used. For the strongest
light signals, use a minimum number of bulkhead splices. See Accessories on page 60.
Non-Hazardous Area Hazardous Area
R T U**
Do not use the Display Module readings to determine if your system is discharged. The display modules only display the system voltage while the gun’s power supply is operating.
Follow the Fluid Voltage Discharge and Grounding
Procedure on page 23 to ensure the system is discharged.
H
KV mA
K
K
K
NOTE:
* The turbine air supply (TA) must be electrically interlocked with the spray booth ventilation fans to prevent the power supply from operating without ventilating fans on.
A
X Y B C D
TA
KV1
KV2
A1 A2
CYL
V**
Q
85.0 KV
TI1797A
S
Fig. 3. Optional Fiber Optic Connection to Voltage Display Module
12 309457E
Installation
Install the Air Line
Accessories
Install the Gun and Mounting
Bracket
1.
Install a bleed-type air valve (L) on the main air line
(W) to shut off all air to the gun (H).
2.
Install an air line filter/water separator on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece and can cause the gun to malfunction.
3.
Install a bleed-type air regulator (M) on each of the air supply lines (B, C, D, E, X, Y) to control air pressure to the gun.
4.
Install a solenoid valve (K) on the cylinder air line (E) to actuate the gun. The solenoid valve must have a quick exhaust port.
1.
Loosen the mounting bracket’s two set screws (103) and slide the bracket (102) onto a 1/2 in. (13 mm)
2.
Position the gun and tighten the two set screws.
For added positioning reliability, insert a 1/8 in. (3 mm) locating pin into the slot (NN) in the bracket and through
a hole in the rod. See the detail in F IG . 4.
2.88 in
(73.2 mm)
102
103
9.22 in TI1570A
(234.2 mm)
To nozzle tip
WARNING
Pressurized Equipment Hazard
Trapped air can cause the gun to spray unexpectedly, which can result in serious injury, including splashing fluid in the eyes or on the skin. The solenoid valves (K) must have a quick exhaust port so trapped air will be relieved between the valve and gun when the solenoids are shut off.
03460
NN
Fig. 4. Mounting Bracket
309457E 13
Installation
Connect the Air Line
F IG . 3. shows a schematic of air line connections, and
F IG . 5. shows the manifold connections. Connect the air
lines as instructed.
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of a fire, explosion, or electric shock, the gun turbine air supply must be interlocked with:
•The isolation system to shut off the turbine air supply anytime the enclosure or safety fence is opened.
•The ventilators to prevent operation of the power supply unless the ventilating fans are on.
WARNING
Electric Shock Hazard
To reduce the risk of electric shock or other serious injury, you must use the red-colored
Graco grounded air hose for the turbine air supply hose, and you must connect the hose ground wire to a true earth ground. Do not use the black or grey-colored Graco air hoses.
1.
Connect the red-colored Graco Grounded Air Supply Hose (B) to the gun's turbine air inlet (TA) and connect the hose ground wire (A) to a true earth ground (N). The gun turbine air inlet fitting has left-hand threads to prevent connecting another type
2.
Check the electrical grounding of the gun as
14 309457E
Installation
Manifold Connections
A1
A2
CYL
EXH
FO
KV1
KV2
P1
P2
TA
Atomization Air Inlet Fitting
Connect a 3/8 in. (10 mm) OD tube between this fitting and the air supply.
Fan Air Inlet Fitting
Connect a 3/8 in. (10 mm) OD tube between this fitting and the air supply.
Cylinder Air Inlet Fitting
Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid. For quicker response, use the shortest hose length possible.
Shroud Exhaust Outlet Fitting
Connect a 1/4 in. (6 mm) OD x 4 ft (1.22 m) long tube to this fitting.
Fiber Optic Fitting (Optional)
Connect the Graco Fiber Optic cable (see page 19).
kV Switch 1 Air Inlet Fitting
Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid.
kV Switch 2 Air Inlet Fitting
Connect a 5/32 in. (4 mm) OD tube between this fitting and the solenoid.
Fluid Supply Inlet
Connect a Graco waterborne fluid hose.
Not used.
Turbine Air Inlet Fitting
Connect the red-colored Graco Grounded Air Hose between this fitting (left-hand thread) and the solenoid.
Connect the air hose ground wire to a true earth ground.
KV2
TA
CYL
A1
P1
Fig. 5. Manifold Connections
TI1790A
KV1
FO
A2
P2
EXH
309457E 15
Installation
Connect the Waterborne
Fluid Hose
CAUTION
Be careful not to cut into the inner tube (T) of the hose when stripping the hose. Nicks or cuts in the
PTFE tube will cause premature hose failure.
CAUTION
The Graco warranty is void if the spray gun is connected to a non-Graco voltage isolation system or if the gun is operated above 60 kV.
• Always use a Graco waterborne fluid hose between the voltage isolation system fluid outlet and the gun
fluid inlet. See page 59 for available Graco water-
borne hoses.
• Before connecting the waterborne fluid hose to the gun, blow it out with air and flush with water to remove contaminants.
A 9.75 in. (248 mm)
B 1.5 in. (38 mm)
A
B
TI1806A
WARNING
Electric Shock Hazard
To reduce the risk of electric shock, install only one continuous Graco waterborne hose between the isolated fluid supply and the gun. Do not splice hoses together.
1.
Remove the air cap (3) and shroud (2). See page
2.
For the fluid hose to seal properly, it must be stripped and assembled to the dimensions shown in
F IG . 6.. Push the inner tube (T) into the barrel fitting
(F) until the tube bottoms. A new Graco waterborne fluid hose comes fully assembled to these dimensions.
T
F
Fig. 6. Waterborne Hose Dimensions
3.
Inspect the o-ring (R) on the barrel fitting (F) of the hose. Replace if worn or damaged. See F
IG
. 7..
4.
Lubricate the o-ring (R) on the barrel fitting (F) with dielectric grease. Screw the fitting into the fluid inlet of the gun barrel (9) and tighten.
5.
Unscrew the strain relief nut (N) from the hose ferrule (M) and slide the nut up the hose.
16 309457E
Installation
9
F
R M*
C
P1
N*
TI1802A
N*
M*
TI1793A
*Ferrule (M) and nut (N) are part of the waterborne hose assembly (purchase separately).
Fig. 7. Connect the Waterborne Fluid Hose
309457E 17
Installation
6.
Slide the inner tube (T) of the hose through the slot and into the fluid inlet port (P1) of the manifold.
Screw the hose ferrule (M) into the port.
10. Connect the other end of the hose to the fluid outlet
of the isolated fluid supply. See F IG . 8..
WARNING
Electric Shock Hazard
To maintain grounding continuity, the conductive hose layer (C) must be engaged in the ferrule (M) when the nut (N) is tightened. Failure to properly install the hose in the fitting could result in an electric shock.
7.
Screw the strain relief nut (N) onto the hose ferrule
(M). Tighten to about 55 in-lb (6.2 N•m). Pull back on the hose to make sure it is secure.
8.
Reinstall the shroud (2) and air cap (3).
9.
Check the gun’s electrical grounding (see page 21).
WARNING
Electric Shock Hazard
To reduce the risk of electric shock, the areas of the waterborne fluid hose that are accessible to personnel during normal operation must be covered by the outer hose jacket (J). The portion of the inner hose layer (T) not covered by the outer jacket must be inside the voltage isolation system enclosure (E).
The conductive hose layer (C) must be grounded through its connection to the isolation system’s grounded enclosure (E).
2
E
3
T C J
TI1805A
Fig. 8. Hose Connection at Isolated Fluid Supply
18 309457E
Installation
Optional Fiber Optic Cable
Connection
5
120
WARNING
Electric Shock Hazard
To reduce the risk of electric shock, do not use the Graco ES Display Module readings to determine if your system is discharged.
The display module will only display the system voltage while the gun’s power supply is oper-
ating. Follow the Fluid Voltage Discharge and
Grounding Procedure on page 23 to ensure that the
system is discharged.
An optional fiber optic fitting is shipped unassembled with the gun. If an ES (kV) display module is used, install the fitting in the FO port of the manifold. See F IG .
3., page 12, for a schematic of the fiber optic connections.
1.
Remove the plug (120) from the fiber optic port, and install the fiber optic fitting (5, shipped loose with the
TI1794A
Fig. 9. Fiber Optic Fitting
2.
Remove the nut (AA) from the fiber optic fitting (5) and slide the nut over the end of the fiber optic cable
3.
Push the cable (BB) into the fitting (5) until it bottoms out. Tighten the nut (AA) to secure the cable.
5
BB
AA
TI1795A
Fig. 10. Fiber Optic Cable
Most of the fiber optic light transmission loss occurs at the bulkhead splices. For the strongest light signals, use a minimum number of bulkhead splices. A maximum of two splices, with a total of 108 ft (33 m) of cable, is recommended.
4.
See manual 308265 to install a Graco ES Display
Module.
309457E 19
Installation
Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
When operating the electrostatic gun, any ungrounded objects in the spray area (people, containers, tools, etc.) can become electrically charged. Improper grounding can result in static sparking, which can cause a fire, explosion, or electric shock.
Follow the grounding instructions below.
The following are minimum grounding requirements for a basic electrostatic waterborne system. Your system may include other equipment or objects which must be grounded. Check your local electrical code for detailed grounding instructions. Your system must be connected to a true earth ground.
• Electrostatic Air Spray Gun: ground the gun by connecting the red-colored Graco Grounded Air Hose to the turbine air inlet and connecting the air hose
ground wire to a true earth ground. See Check
Electrical Grounding, page 21.
• Graco Waterborne Fluid Hose: the hose is grounded through the conductive layer. Install the hose as
• Voltage Isolation System: electrically connect to a true earth ground.
• Air compressors and hydraulic power supplies: ground the equipment according to the manufacturer's recommendations.
• All air and fluid lines must be properly grounded.
• All electrical cables must be properly grounded.
• All persons entering the spray area: shoes must have conductive soles, such as leather, or personal grounding straps must be worn. Do not wear shoes with non-conductive soles such as rubber or plastic.
• Object being sprayed: keep the workpiece hangers clean and grounded at all times. Resistance must not exceed 1 megohm.
• The floor of the spray area: must be electrically conductive and grounded. Do not cover the floor with cardboard or any non-conductive material which would interrupt grounding continuity.
• Flammable liquids in the spray area: must be kept in approved, grounded containers. Do not use plastic containers. Do not store more than the quantity needed for one shift.
• All electrically conductive objects or devices in the
spray area: including fluid containers and wash cans, must be properly grounded.
20 309457E
Installation
Check Electrical Grounding
WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
F IG . 11.) is not approved for use in a hazardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:
•The gun has been removed from the hazardous area;
•Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area
(such as open solvent containers or fumes from spraying).
Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.
1.
Have a qualified electrician check the electrical grounding continuity of the spray gun and turbine air hose.
2.
Make sure the red-colored turbine air hose (B) is connected and the hose ground wire is connected to a true earth ground.
3.
Turn off the air and fluid supply to the gun. The fluid hose must not have any fluid in it.
4.
Measure the resistance between the turbine air inlet fitting (TA) and a true earth ground (N), using an ohmmeter. The resistance should not exceed 100 ohms.
5.
If the resistance is greater than 100 ohms, check the tightness of the ground connections and be sure the turbine air hose ground wire is connected to a true earth ground. If the resistance is still too high, replace the turbine air hose.
N
B
AA
TA
TI1798A
Fig. 11. Check Gun Grounding
309457E 21
Installation
Install the Fabric Cover
1.
Install a fabric cover (XX) over the front of the gun and slide it back to cover the exposed tubing and
hoses at the back of the manifold. See F IG . 12..
2.
Route the exhaust tube (YY) outside the cover. This enables you to monitor the exhaust tube for the
presence of any paint or solvent. See Check for
Fluid Leakage on page 33. Strap down the exhaust
tube to prevent it from moving around.
YY
Fig. 12. Fabric Cover
XX ti1787A
YY
TI1792A
22 309457E
Operation
Operation
Fluid Voltage Discharge and
Grounding Procedure
WARNING
Electric Shock Hazard
The high voltage fluid supply is charged with high voltage until the voltage is discharged. Contact with the charged components of the isolation system or spray gun electrode will cause an electric shock. To avoid an
electric shock, follow the Fluid Voltage Discharge
• when instructed to discharge the voltage
• before cleaning, flushing, or servicing the system equipment
• before approaching the front of the gun
• or before opening the safety fence or enclosure for the isolated fluid supply.
An accessory grounding rod, part No. 210084, is available to discharge any voltage remaining on a system component. Contact your Graco distributor to order.
1.
Turn off the turbine air to all spray guns connected to the isolated fluid supply.
2.
Discharge the voltage at the voltage isolation system by following the procedure specified in the voltage isolation system instruction manual.
3.
Touch the electrode of the gun with a grounded rod to make sure the voltage has been discharged. If you see an arc, verify that the electrostatics are
turned off or see Electrical Troubleshooting on page 42 or the voltage isolation system manual for
other possible problems. Resolve the problem before proceeding.
309457E 23
Operation
Pressure Relief Procedure
WARNING
Pressurized Equipment Hazard
The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from electric shock, accidental spray from the gun, splashing fluid, or moving parts, follow the
Pressure Relief Procedure whenever you:
• are instructed to relieve the pressure
• stop spraying
• check or service any of the system equipment
• or install or clean the fluid nozzle.
1.
Follow the Fluid Voltage Discharge and Ground-
2.
Relieve fluid pressure in the fluid supply and voltage isolation system as instructed in their instruction manuals.
3.
Turn off all the air to the spray gun except the cylinder air, which triggers the gun. If an air pilot fluid regulator is used in the system, air pressure is also needed at the regulator air inlet.
The air shut-off device must bleed the air out of the system.
4.
Trigger the gun into a grounded metal waste container to relieve the fluid pressure.
5.
Turn off all remaining air supplies to the gun.
6.
Turn off the main air supply by closing the bleed-type master air valve on the main air supply line. Leave the valve closed until you are ready to spray again.
Operating Checklist
Check the following list daily, before starting to operate the system, to help ensure you of safe, efficient operation.
All operators are properly trained to safely operate an automatic electrostatic waterborne air spray system as instructed in this manual.
All operators are trained in the Fluid Voltage
Discharge and Grounding Procedure on page 23.
All operators are trained in the Pressure
The warning sign provided with the gun is mounted in the spray area where it can be easily seen and read by all operators.
The system is thoroughly grounded and the operator and all persons entering the spray
area are properly grounded. See Grounding on page 20.
The condition of the gun’s electrical compo-
nents has been checked as instructed in Elec-
All fluid hose connections are tight.
Ventilation fans are operating properly.
Workpiece hangers are clean and grounded.
All debris, including flammable fluids and rags, is removed from the spray area.
All conductive objects in the spray area are electrically grounded and the floor of the spray area is electrically conductive and grounded.
The manifold exhaust tubes have been checked for the presence of any fluid as
instructed in Check for Fluid Leakage on page 33.
24 309457E
Operation
Select a Fluid Nozzle and Air
Cap
Part No.
197263
197264
197265
Table 2: Fluid Nozzles
Size, mm (in.)
0.75 (.030)
1.0 (.042)
1.2 (.047)
Part No.
197266
197267
197268
Size, mm (in.)
1.5 (.055)
1.8 (.070)
2.0 (.080)
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 24
before removing or installing a fluid nozzle and/or air cap.
The gun is supplied with Part No. 197266 Nozzle and
197477 Air Cap. If you require a different size, refer to
Table 2 and Table 3 , and instruction manual 309419, or
consult with your Graco distributor. See Air Cap/Nozzle
Part No.
197477
197478
197479
197480
197481
Table 3: Air Caps
Pattern Shape and Length in. (mm)
Round end;
15-17 (381-432)
Round end;
15-17 (381-432)
Tapered end;
13-15 (330-381)
Round end;
16-18 (406-457)
Tapered end;
17-19 (432-483)
Recommended Fluids and
Production Rates
Light to medium viscosity.
Medium to high production.
Light to medium viscosity.
Low to medium production.
Light to medium viscosity.
Medium to high production.
Medium to high viscosity and high solids.
Low to medium production.
Medium to high viscosity and high solids.
Medium to high production.
For use with 2.0 mm nozzle.
309457E 25
Operation
Adjust the Spray Pattern
Follow the steps below to establish the correct fluid flow and air flow. Do not turn on the turbine air (TA) yet.
WARNING
Fire and Explosion Hazard
To reduce the risk of fire and explosion, only use this equipment with fluids that meet at least one of the following conditions for non-flammability:.
• The fluid has a flash point above 140
°
F (60
°
C) and a maximum organic solvent concentration of
20%, by weight, per ASTM Standard D93.
• The fluid does not sustain burning when tested per ASTM Standard D4206 Sustained Burn Test.
WARNING
Component Rupture Hazard
To reduce the risk of component rupture, which can cause serious injury, do not exceed the maximum working pressure of the lowest rated system component. This equipment has a 100 psi (0.7 MPa, 7 bar) maximum working air and fluid pressure.
WARNING
Electric Shock Hazard
Contact with the charged components of the spray gun will cause an electric shock.
Do not touch the gun nozzle or electrode or come within 2 ft (0.61 m) of the front of the
gun during operation or until performing the Fluid
Voltage Discharge and Grounding Procedure on page 23.
Follow the Fluid Voltage Discharge and Grounding
Procedure on page 23 when you stop spraying and
whenever you are instructed to discharge the voltage.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 24
whenever you are instructed to relieve the pressure.
1.
Discharge the system voltage (page 23).
2.
Relieve the pressure (page 24).
3.
Loosen the air cap retaining ring, and rotate the air cap for a vertical or horizontal spray pattern. See
F IG . 13.. Tighten the retaining ring until the air cap is
held firmly in place; you should not be able to rotate the air cap horns by hand.
Vertical Pattern
Horizontal Pattern
Fig. 13. Air Cap Positions
26 309457E
Operation
4.
Adjust the fluid flow with the fluid pressure regulator.
Refer to instruction manual 309419 to set the fluid pressure for various fluid flows, according to the size of the fluid nozzle being used.
5.
Use the air pressure regulator on the atomization air supply line (A1) to adjust the degree of atomization.
See F IG . 14.. For example, for a fluid flow rate of 10 ounces per minute (0.3 liters per minute), a typical atomization pressure would be 20-30 psi (1.4-2.1 bar, 0.14-0.21 MPa) at the gun manifold.
6.
Use the air pressure regulator on the fan air supply line (A2) to adjust the pattern size.
KV2
TA
CYL
A1
• For the most efficiency, always use the lowest air pressure possible.
• When increasing to a wide, flat pattern, it may be necessary to increase the supply of fluid to the gun to maintain the same amount of coverage over a large area.
•
See Spray Pattern Troubleshooting on page 40 to
correct spray pattern problems.
TI1790A
Fig. 14. Manifold Air Connections
KV1
A2
309457E 27
Operation
Adjust the Electrostatics
1.
Shut off the fluid supply.
2.
Prepare the isolation system for high voltage operation.
3.
Trigger the gun, then turn on the turbine air (TA).
See F IG . 14..
4.
Refer to Table 4 to set the proper pressure at the
turbine air hose inlet when air is flowing. Do not exceed these pressures as there is no added benefit and turbine life could be reduced.
Table 4: Turbine Air Pressures
Turbine Air
Hose Length ft (m)
15 (4.6)
25 (7.6)
36 (11)
50 (15.3)
75 (22.9)
100 (30.5)
Air pressure at turbine air hose inlet for full voltage psi (bar, MPa)
54 (3.8, 0.38)
55 (3.85, 0.38)
56 (3.9, 0.39)
57 (4.0, 0.40)
59 (4.1, 0.41)
61 (4.3, 0.43)
5.
Check the voltage output of the gun using a high voltage probe and meter or by reading the ES (kV)
Display Module.
The gun’s normal high voltage reading is 45-55 kV.
See Electrical Troubleshooting on page 42 to correct
voltage problems.
28 309457E
Operation
Spraying
WARNING
Electric Shock Hazard
To reduce the risk of electric shock, do not touch the gun electrode or come within 2 ft
(6.1 m) of the nozzle during gun operation.
1.
Apply a minimum of 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to activate the on/off sequence of atomization air (A1), fan air
(A2), and fluid (P1). See F IG . 14..
2.
Turn the gun functions on and off by using the air solenoid valves on the cylinder (CYL) and turbine
(TA) air supply lines.
3.
To change to a lower voltage setting, activate the solenoids controlling the KV1 and KV2 ports. See
Changing the kV Setting on page 8.
WARNING
Fire and Explosion Hazard
If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury
and property damage. See Check for Fluid
Triggering the Fluid Alone
1.
Shut off and relieve the air pressure to the atomization (A1) and fan (A2) air lines, using the bleed-type air shutoff valves.
2.
Apply 50 psi (3.5 bar, 0.35 MPa) air pressure to the cylinder air fitting (CYL) to trigger the fluid.
Shutdown
1.
Discharge the system voltage (page 23).
2.
Flush and clean the equipment. See Maintenance on page 30.
3.
Relieve the pressure (page 24).
309457E 29
Maintenance
Maintenance
Daily Care and Cleaning
CAUTION
• Clean all parts with a non-conductive, compatible solvent. Conductive solvents can cause the gun to malfunction.
Do not immerse the gun in fluid.
• Do not use methylene chloride as a flushing or cleaning solvent with this gun as it will damage nylon components.
• Fluid in the air passages could cause the gun to malfunction and could draw current and reduce the electrostatic effect. Fluid in the power supply cavity can reduce the alternator life. Whenever possible, point the gun down when cleaning it. Do not use any cleaning method which could allow fluid into the gun air passages.
Do not point the gun up while cleaning it.
TI1788A
Do not wipe the gun with a cloth that is heavily saturated; wring out the excess fluid.
02027A
TI1789A
30 309457E
Maintenance
Daily Care and Cleaning, continued
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 24
before doing any maintenance on the gun or system.
• Clean the fluid and air line filters daily.
• Clean the outside of the gun daily with a soft cloth dampened in a compatible solvent.
• Clean the air cap and fluid nozzle daily, minimum.
Some applications require more frequent cleaning.
Replace the fluid nozzle and air cap if they are dam-
aged. See Clean the Air Cap and Fluid Nozzle, page 32.
• Check the electrode and replace if broken or dam-
aged. See Electrode Replacement on page 46.
• Check for fluid leakage from the gun and fluid
hoses. See Check for Fluid Leakage on page 33.
Tighten fittings or replace equipment as needed.
• Flush the gun before changing colors and whenever you are done operating the gun.
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of fire, explosion, or electric shock, turn off the turbine air (TA) before flushing the gun or any part of the system.
309457E 31
Maintenance
Clean the Air Cap and Fluid
Nozzle
Equipment Needed
• soft bristle brush
• compatible solvent
Procedure
1.
Discharge the system voltage, page 23.
2.
Relieve the pressure, page 24.
3.
Remove the air cap assembly (1, 3) and shroud (2).
4.
Wipe the fluid nozzle (4), shroud (2), and exterior of the gun clean with a cloth dampened in non-flammable solvent. Avoid getting any solvent into the air passages. Whenever possible, point the gun down when cleaning it.
5.
If it appears that there is fluid inside the fluid nozzle
(4) air passages, remove the gun from the line for servicing.
6.
Clean the air cap (3) with the soft bristle brush and solvent or submerge the air cap in suitable solvent and wipe it clean.
7.
Slide the shroud (2) onto the gun.
8.
Carefully install the air cap (3). Be sure to insert the electrode (7) through the center hole of the air cap.
Rotate the air cap to the desired position.
9.
Make sure the u-cup (1a) is in place on the retaining ring (1). The lips must face forward. Tighten the retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.
10. Test gun resistance, page 34.
3
1
2
1a 7 4
Fig. 15. Clean Air Cap and Fluid Nozzle
TI1779A
CAUTION
Do not use metal tools to clean the air cap or fluid nozzle holes as this could scratch them, and make sure the electrode is not damaged.
Scratches in the air cap or nozzle or a damaged electrode can distort the spray pattern.
32 309457E
Maintenance
Check for Fluid Leakage
WARNING
Fire and Explosion Hazard
If any fluid leakage from the gun is detected, stop spraying immediately. Fluid leakage into the gun shroud could cause fire or explosion and result in serious injury and property damage.
During operation, periodically check the manifold exhaust tube (YY) and both ends of the gun shroud (ZZ)
for the presence of fluid. See F IG . 16.. Fluid in these
areas indicates leakage into the shroud, which could be caused by leaks at the fluid tube connections or fluid packing leakage.
If fluid is seen in these areas, stop spraying immediately.
Discharge the voltage (page 23), relieve the pressure
(page 24), and then remove the gun for repair.
YY
ZZ
Fig. 16. Check for Fluid Leakage
ZZ ti1787A
YY
TI1792A
309457E 33
Electrical Tests
Electrical Tests
Electrical components inside the gun affect performance and safety. The following procedures test the condition of the power supply (12) and electrode (7), and electrical continuity between components.
Use megohmmeter Part No. 241079 (AA) and an applied voltage of 500 V. Connect the leads as shown.
Test Gun Resistance
1.
Flush and dry the fluid passage.
2.
Measure resistance between the electrode needle tip (7) and the turbine air inlet fitting (TA); it should be 117-137 megohms. If outside this range, remove
the gun for service (page 43) and go to the next test.
mance. WARNING
Fire, Explosion, and Electric Shock Hazard
Megohmmeter Part No. 241079 (AA-see
F IG . 17.) is not approved for use in a haz-
ardous area. To reduce the risk of sparking, do not use the megohmmeter to check electrical grounding unless:
•The gun has been removed from the hazardous area;
•Or all spraying devices in the hazardous area are turned off, ventilation fans in the hazardous area are operating, and there are no flammable vapors in the area
(such as open solvent containers or fumes from spraying).
Failure to follow this warning could cause fire, explosion, and electric shock and result in serious injury and property damage.
AA
TA
TA
TI1790A
7
TI1799A
Fig. 17. Test Gun Resistance
34 309457E
Electrical Tests
Test Power Supply
Resistance
6.
Be sure the spring (12b) is in place before reinstalling the power supply.
1.
Remove the power supply (12), page 53.
2.
Remove the turbine alternator (13) from the power
3.
Measure resistance from the power supply's ground
strips (EE) to the spring (12b). See F IG . 18..
4.
The resistance should be 95-105 megohms. If outside this range, replace the power supply. If in range, proceed to the next test.
5.
If you still have problems, refer to Electrical Trou-
bleshooting on page 42 for other possible causes
of poor performance, or contact your Graco distributor.
12b
Fig. 18. Test Power Supply Resistance
EE ti1599a
309457E 35
Electrical Tests
Test Electrode Resistance
1.
Insert a conductive rod (B) into the gun barrel
(removed for the power supply test) and against the metal contact (C) in the front of the barrel.
2.
Measure the resistance between the conductive rod
(B) and the electrode (7). The resistance should be
20-30 megohms. See F IG . 19..
3.
mance, or contact your Graco distributor.
4.
Remove the electrode (7), page 46. Measure the
resistance between the contact (E) and the electrode wire (F). The resistance should be 20-30 megohms. If out of range, replace the electrode.
5.
Make sure the metal contact (C) in the barrel, the
nozzle contact ring (4a, F IG . 21.), and the electrode
contacts (E) are clean and undamaged.
F
Fig. 20. Electrode
7 E ti1513a
Fig. 21. Nozzle Conductive O-Ring
4a ti1548a
C
7
Fig. 19. Test Electrode Resistance
B ti1499a
36 309457E
Troubleshooting
Troubleshooting
WARNING
Electric Shock Hazard
Installing and servicing this equipment requires access to parts which may cause an electric shock or other serious injury if the work is not performed properly. Do not install or repair this equipment unless you are trained and qualified.
Follow the Fluid Voltage Discharge and Grounding
Procedure on page 23 before checking or servicing
the system and whenever you are instructed to discharge the voltage.
WARNING
Pressurized Equipment Hazard
To reduce the risk of an injury, follow the
Pressure Relief Procedure on page 24
before checking or servicing any part of the system and whenever you are instructed to relieve the pressure.
Voltage Loss
Troubleshooting
Normal spraying voltage for a system using the waterborne gun is 45-55 kV. The system voltage is lower due to spraying current demands and voltage isolation system losses.
A loss of spraying voltage can be caused by a problem with the spray gun, fluid hose, or voltage isolation system, since all of the system components are electrically connected through the conductive, waterborne fluid.
Before troubleshooting or servicing the voltage isolation system itself, you need to determine which component in the system is most likely causing a problem. Possible causes include the following:
Spray Gun
• Fluid leakage
• Dielectric breakdown at the fluid hose connection or fluid packings
• Not enough air pressure for the turbine
• Faulty power supply
• Excessive overspray on gun surfaces
• Fluid in the air passages
Waterborne Fluid Hose
• Dielectric failure of hose (pin-hole leak through
PTFE layer)
• Air gap in the fluid column between the gun and isolated fluid supply, causing a low voltage reading on the isolation system voltage meter.
Voltage Isolation System
• Fluid leakage
• Dielectric breakdown of hoses, seals, or connections
• Isolators not functioning properly
309457E 37
Troubleshooting
Visual Check
First, check the system for any visible faults or errors to help isolate whether the spray gun, fluid hose or voltage isolation system has failed. A voltage probe and meter, part no. 236003, is helpful for diagnosing voltage problems and is required for some of the troubleshooting tests that follow.
1.
Check that all of the air and fluid tubes and hoses are properly connected.
2.
Check that the voltage isolation system valves and controls are properly set for operation.
3.
Check that the spray gun and voltage isolation system have sufficient air pressure.
4.
Check that the gun turbine air (TA) is turned on and the pressure is set correctly.
5.
Check that the voltage isolation system's enclosure door is closed and that any safety interlocks are engaged and working properly.
6.
Make sure the voltage isolation system is in the “isolate” mode, where it is isolating the fluid voltage from ground.
7.
To eliminate air gaps in the fluid column, spray enough fluid to purge the air out between the voltage isolation system and the spray gun. An air gap in the fluid hose can break the electrical continuity between the spray gun and the isolated fluid supply and cause a low voltage reading on a voltage meter connected to the isolated fluid supply.
8.
Check the spray gun cover and barrel for accumulated overspray. Excessive overspray can create a conductive path back to the grounded gun. Install a new gun cover and clean the exterior of the gun.
9.
Inspect the entire system for any visible fluid leakage and repair any fluid leaks that are found. Pay special attention to the following areas:
• Packing area of the spray gun
• Fluid hose: check for leakage or any bulges in the outer cover, which may indicate an internal leak
• Internal voltage isolation system components
Tests
If you still have no voltage, separate the spray gun and hose from the voltage isolation system and check whether the gun and hose alone will hold voltage with the following test.
1.
Flush the system with water and leave the lines filled with water.
2.
Discharge the system voltage (page 23).
3.
Relieve the pressure (page 24).
4.
Disconnect the fluid hose from the voltage isolation system.
Avoid allowing any water to leak out of the fluid hose as that could cause a significant air gap in the fluid column up to the gun electrode, which can break the conductivity path and conceal a potential failure area.
5.
Position the end of the hose as far as possible away from any grounded surface. The end of the hose must be at least 1 ft. (0.3 m) from any ground. Make sure that no one is within 3 ft. (0.9 m) of the end of the hose.
6.
Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and meter.
7.
Discharge the system voltage by waiting 30 seconds and then touching the gun electrode with a grounded rod.
8.
If the meter reading is 45 to 55 kV, the gun and fluid hose are okay, and the problem is in the voltage isolation system.
If the reading is below 45 kV, the problem is in the gun or fluid hose.
9.
Flush the fluid hose and gun with enough air to dry out the fluid passages.
10. Turn the turbine air to the gun on. Measure the voltage at the gun electrode with a voltage probe and meter.
38 309457E
Troubleshooting
11. If the meter reading is 55-60 kV, the gun power supply is okay, and there is probably a dielectric breakdown somewhere in the fluid hose or gun. Continue with step 12.
If the reading is below 55 kV, do the electrical tests
on page 34 to check the gun and power supply
resistance. If those tests show the gun and power supply are okay, continue with step 12.
12. A dielectric breakdown is most likely in one of the following three areas. Repair or replace the component that is failing.
• Fluid hose
Check for leakage or any bulges in the outer cover, which may indicate a pin-hole leak through the
PTFE layer. Disconnect the fluid hose from the gun, and look for signs of fluid contamination on the outside of the PTFE portion of the fluid tube.
Inspect the end of the hose connected to the voltage isolation system. Look for cuts or nicks.
Make sure the hose is properly stripped. Restrip or replace the hose.
• Fluid packings
Remove the packing assembly from the gun as
instructed on page 47, and look for signs of fluid
leakage or any blackened areas, which would indicate arcing is occurring along the packing rod.
• Fluid hose connection joint to the spray gun
A breakdown at the fluid hose connection joint would be caused by fluid leaking past the o-ring seals on the end of the hose. Remove the hose at the gun connection and look for signs of fluid leakage along the PTFE tube.
13. Before reassembling the gun, clean and dry the gun fluid inlet tube. Repack the inner spacer of the fluid packing rod with dielectric grease and reassemble the gun.
14. Reconnect the fluid hose.
15. Check the gun voltage with the voltage probe and meter before filling the gun with fluid.
309457E 39
Troubleshooting
Spray Pattern Troubleshooting
Check all possible remedies in the Troubleshooting Chart before disassembling the gun.
Some spray pattern problems are caused by the improper balance between air and fluid.
Problem
Fluttering or spitting spray.
Cause Solution
No fluid.
Refill supply.
Loose, dirty, damaged nozzle/seat.
Clean or replace nozzle, page 45.
Improper spray pattern.
Streaks.
Air in fluid supply.
Damaged nozzle or air cap.
Check fluid source. Refill.
Fluid buildup on air cap or nozzle.
Fan air pressure too high.
Fluid too thin.
Fluid pressure too low.
Fan air pressure too low.
Decrease.
Increase viscosity.
Increase.
Increase.
Fluid too thick.
Too much fluid.
Did not apply 50% overlap.
Dirty or damaged air cap.
Reduce viscosity.
Decrease flow.
Overlap strokes 50%.
40 309457E
Troubleshooting
Gun Operation Troubleshooting
Problem Cause Solution
Excessive spray fog.
“Orange Peel” finish.
Fluid leaks from the fluid packing area
Air leaks from the air cap
Fluid leakage from the front of the gun
Atomizing air pressure too high.
Fluid too thin.
Atomizing air pressure too low.
Poorly mixed or filtered fluid.
Fluid too thick.
Worn packings or rod.
Worn piston stem o-rings (34e, 34f).
Worn or damaged packing rod (8).
Decrease air pressure as low as possible.
Increase viscosity.
Increase air pressure; use lowest air pressure necessary.
Remix or refilter fluid.
Reduce viscosity.
Replace packings or rod; see pages
Gun does not spray
Dirty air cap
Air leaks from manifold
Worn fluid seat.
Loose fluid nozzle (4).
Damaged nozzle o-ring (4b).
Low fluid supply.
Damaged air cap (3).
Dirty or clogged fluid nozzle (4).
Damaged fluid nozzle (4).
Replace fluid nozzle (4) and/or elec-
trode needle (7); see pages 45 to 46.
Add fluid if necessary.
Piston (34) not actuating.
Check cylinder air. Check piston
Actuator arm (29) is out of position.
Check actuator arm and nuts. See
Misaligned air cap (3) and fluid nozzle (4).
Damaged nozzle orifice.
Fluid is coming on before the air.
Manifold is not tight.
Fluid leaks at the quick-disconnect.
Manifold is not tight.
Fluid hose o-rings are worn or missing.
Hose not seated properly.
Clean fluid buildup off air cap and
fluid nozzle seat; see page 32.
Replace nozzle (4); see page 45.
Check actuator arm and nuts. See
Tighten manifold screws (106).
Tighten manifold screws (106).
Inspect or replace o-rings.
Make sure the hose was stripped and
installed correctly. See page 16.
309457E 41
Troubleshooting
Electrical Troubleshooting
Problem Cause Solution
Voltage still present at gun after fol-
lowing the Fluid Voltage Discharge and Grounding Procedure
Turbine air is not turned off.
Turn off.
Poor wrap.
Did not wait long enough for voltage to discharge.
Air pocket in fluid line leaves fluid near gun isolated.
Voltage isolation system failed.
Turbine air is not turned on.
Booth exhaust velocity is too high.
Atomizing air pressure too high.
Poorly grounded parts.
Faulty gun resistance.
Wait longer before touching electrode with grounded rod. Check for bleed resistor failure.
Determine cause and correct. Purge air from fluid line.
Service voltage isolation system.
Turn on.
Reduce velocity to within code limits.
Decrease.
Fluid pressure too high.
Decrease.
Incorrect distance from gun to part.
Should be 8-12 in. (200-300 mm).
Resistance must be 1 megohm or less. Clean workpiece hangers.
See Test Gun Resistance on page
Low fluid resistivity.
Fluid leaks from the packing (8d) and causes a short.
Check fluid resistivity, page 22.
Clean the packing rod cavity.
Replace the packing rod. See page
No voltage or low voltage reading on the gun ES display module
Operator gets mild shock.
Faulty turbine alternator.
The KV switch is stuck on low.
Be sure the plug is in place on the back of the turbine alternator housing. Remove and test the turbine
Check the switch actuation; replace if needed.
No power.
Damaged fiber optic cable or connection.
Turbine air is not turned on.
Poor wrap.
Replace power supply. See page 53.
Check; replace damaged parts.
Turn on.
See causes and solutions under Poor
Wrap, above.
Operator not grounded or is near ungrounded object.
Gun not grounded.
Operator gets shock from workpiece. Workpiece not grounded.
See Check Electrical Grounding on
page 21 and Test Gun Resistance on page 34.
Resistance must be 1 megohm or less. Clean workpiece hangers.
42 309457E
Repair
Repair
Prepare the Gun for Service
WARNING
Fire, Explosion, and Electric Shock Hazard
To reduce the risk of a fire, explosion, or electric shock:
•Follow the Fluid Voltage Discharge and
Grounding Procedure on page 23
before flushing, checking, or servicing the system and whenever you are instructed to discharge the voltage.
•Clean all the parts with a non-flammable solvent as defined on the front cover of this manual.
•Do not service this equipment unless you are trained and qualified.
•Do not come within 2 ft (0.6 m) of the gun nozzle during gun operation or until after
following the Fluid Voltage Discharge and Grounding Procedure.
•
Check all possible remedies in Troubleshooting
before disassembling the gun.
• Use a vise with padded jaws to prevent damage to plastic parts.
• Lubricate the power supply o-ring (12a), some packing rod parts (8), and certain fluid fittings with Part
No. 116553 Dielectric Grease, as specified in the text.
• Lightly lubricate o-rings and seals with non-silicone grease. Order Part No. 111265 Lubricant. Do not over-lubricate.
• Only use genuine Graco parts. Do not mix or use parts from other PRO Gun models.
1.
Discharge the system voltage, page 23.
2.
Flush and clean the gun, page 30.
3.
Relieve the pressure, page 24.
4.
Remove the gun from the manifold, page 44.
5.
Remove the gun from the worksite. Repair area must be clean.
WARNING
Pressurized Equipment Hazard checking or servicing any part of the system and whenever you are instructed to relieve the pressure.
To reduce the risk of injury, follow the Pres-
sure Relief Procedure on page 24 before
309457E 43
Repair
Remove the Gun from the
Manifold
1.
Discharge the system voltage, page 23.
2.
Flush and clean the gun, page 30.
3.
Relieve the pressure, page 24.
4.
Remove the air cap (3) and shroud (2), page 45.
5.
Disconnect the fluid hose fitting (F) from the gun barrel (9).
6.
Loosen the bottom gun screw (31) until the gun sits
loosely in the mounting bracket slot (A). See F IG .
9
112
105
A
F
Fig. 22. Remove Gun from Manifold
102
TI1778A
CAUTION
The piston return spring (105) is compressed between the manifold and the gun body when they are assembled. To avoid sudden movement of the gun, loosen the bottom gun screw (31) before loosening the three manifold screws (106). This allows the gun to move forward gradually as the manifold screws are loosened. Hold the gun firmly in hand while loosening the manifold screws.
7.
Holding the gun firmly in hand, loosen the three screws (106) from the back of the manifold.
8.
Remove the gun from the manifold and take it to the service area.
Install the Gun on the
Manifold
1.
Make sure the gasket (112) and spring (105) are in
parts for damage and replace them as needed.
2.
Secure the gun to the manifold by tightening the three screws (106).
3.
Secure the gun to the mounting bracket (102) by tightening the bottom screw (31).
4.
Make sure the fittings and barrel are clean and dry,
then reconnect the waterborne fluid hose, page 16.
5.
Reinstall the gun shroud (2) and air cap (3), page
44 309457E
Repair
Air Cap/Nozzle Replacement
CAUTION
Hold the front end of the gun up and trigger the gun while removing the nozzle to help drain the gun and prevent any paint or solvent left in the gun from entering the air passages.
1.
Prepare gun for service, page 43.
2.
Remove the retaining ring (1) and air cap (3). See
3.
Point gun up while removing the fluid nozzle (4) assembly with the multi-tool (40).
1, 3
40
1
4
7
4
4a
4b
TI1572A
Fig. 23. Air Cap/Nozzle Replacement
1a
3
WARNING
Fire, Explosion, and Electric Shock Hazard
The nozzle contact ring (4a) is a conductive contact ring, not a sealing o-ring. To reduce the risk of sparking or electric shock, do not remove the nozzle contact ring (4a) except to replace it and never operate the gun without the contact ring in place. Do not replace the contact ring with anything but a genuine
Graco part.
Use non-silicone grease, Part No. 111265, on the small o-ring (4b). Do not over-lubricate. Do not lubricate the contact ring (4a).
4.
Lightly lubricate the o-ring (4b). Install it and the contact ring (4a) on the nozzle (4).
Make sure the electrode needle (7) is finger- tight (page
5.
Install the fluid nozzle (4) with the multi-tool (40).
Tighten until the fluid nozzle seats in the gun barrel
(1/8 to 1/4 turn past hand-tight).
6.
Carefully install the air cap (3). Be sure to insert the electrode (7) through the center hole of the air cap.
Rotate the air cap to the desired position.
7.
Make sure the u-cup (1a) is in place on the retaining ring (1). The lips must face forward. Tighten the retaining ring until the air cap is held firmly in place; you should not be able to rotate the air cap horns by hand.
8.
9.
Install the gun onto the manifold and bracket. See
309457E 45
Repair
Electrode Replacement
1.
Prepare the gun for service, page 43.
2.
Remove the air cap and nozzle, page 45. Remove
the gun shroud (2).
3.
Unscrew the electrode (7) with the multi-tool (40).
Hold the packing rod end (8h) to prevent it from turn-
40
CAUTION
To avoid damaging the plastic threads, be very careful when installing the electrode.
4.
Apply low-strength (purple) Loctite® or equivalent thread sealant to the electrode and packing rod threads. Install the electrode finger-tight. Do not overtighten.
5.
Install the fluid nozzle, page 45.
6.
7.
Install the gun shroud (2) and air cap, page 45.
8.
Install the gun onto the manifold and bracket. See
8h
Fig. 24. Electrode Replacement
TI1782A
46 309457E
Repair
Fluid Packing Removal
You may replace the packing rod as an assembly, as
described below, or as individual parts (see page 48).
The assembly is pre-adjusted at the factory.
1.
Prepare the gun for service, page 43.
2.
Remove the air cap, page 45. Remove the gun
shroud (2).
3.
Remove the jam nut (28) and actuator arm (29). See
The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.
4.
Remove the fluid nozzle (4) and electrode (7). See
5.
Remove the packing rod (8), using the multi-tool
(40).
Before installing the packing rod, clean the internal surface of the barrel (9) with a soft cloth or brush. Check for marks from high voltage arcing. If marks are present, replace the barrel.
40
9
CAUTION
Clean all parts in non-conductive solvent compatible with the fluid being used, such as xylol or mineral spirits. Use of conductive solvents can cause the gun to malfunction.
6.
Check all parts for wear or damage and replace if necessary.
28
Fig. 25. Fluid Packing Removal
TI1783A
309457E 47
Repair
Packing Rod Repair
You may replace the packing rod as individual parts, as
described below, or as an assembly (see page 47). The
assembly is pre-adjusted at the factory.
Before installing the fluid packing rod into the gun barrel, make sure the internal surfaces of the barrel are clean.
Remove any residue with a soft brush or cloth. Check the inside of the barrel for marks from high voltage arcing. If marks are present, replace the barrel.
To assemble the individual parts:
1.
Place the packing nut (8e) and seal (8b) on the fluid rod (8h). Flats on the packing nut must face the back of the fluid rod. The seal o-ring must face away
from the packing nut. See F IG . 26..
2.
Fill the inner cavity of the spacer (8g) with dielectric grease. Place the spacer on the fluid rod (8h) in the direction shown. Generously apply dielectric grease to the outside of the spacer.
3.
Place the rod packing (8d), packing spreader (8c), and housing (8f) on the packing rod (8h).
4.
Lightly tighten the packing nut (8e). The packing nut is properly tightened when there is 3 lb (13.3 N) of drag force when sliding the packing housing (8f) assembly along the rod. Tighten or loosen the packing nut as needed.
5.
Install the o-ring (8a) on the outside of housing (8f).
Lubricate the o-ring with non-silicone grease, Part
No. 111265. Do not over-lubricate.
6.
Install the spring (25) against the nut (E) as shown.
7.
Install the packing rod assembly (8) into the gun barrel. Using the multi-tool (40), tighten the assembly until just snug.
8.
Install the electrode, page 46 and nozzle, page 45.
9.
Install and adjust the actuator arm (29) and jam nut
10. Test gun resistance, page 34.
11. Install the gun shroud (2) and air cap, page 45.
12. Install the gun onto the manifold and bracket. See
E
25
TI1489A
8h
8c
8d
8g
8b
8e
8f
8a
Fig. 26. Packing Rod
48 309457E
Repair
Piston Repair
1.
Prepare the gun for service, page 43.
2.
Remove the air cap, page 45. Remove the gun
shroud (2).
3.
Remove the jam nut (28), actuator arm (29), and
adjustment nut (30). See F IG . 27..
The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.
Table 5: Piston O-Rings
Description
Shaft O-Ring
(34g)
Front O-Ring
(34e)
Back O-Ring
(34f)
U-Cup (34d)
Function
Seals cylinder air along the piston rod
(34b). Replace if air leaks along rod.
Air shutoff seal. Replace if air leaks from air cap when gun is de-triggered.
Separates cylinder air from fan and atomizing air.
Replace if air leaks from small vent hole at back of manifold when gun is triggered.
TI1800A
28 29 30 34b
Fig. 27. Actuator Arm
4.
Push on the piston rod (34b) to push the piston out the back of the gun.
5.
Inspect the o-rings (34e, 34f, 34g) and u-cup pack-
ing (34d) for damage. See Table 5 and F
6.
Lubricate the o-rings (34e, 34f, 34g) and u-cup packing (34d) with non-silicone grease, Part No.
111265. Do not over-lubricate.
7.
Align the two stems (34c) with the holes in the gun body and press the piston assembly into the back of the gun until it bottoms.
8.
Install and adjust the actuator arm, page 50.
34a
34c
34d
34e
34f
TI1575A
34g
34e
34f
34b
34d
Fan Air Side
Atomizing Air Side
34g
TI1576A
Fig. 28. Piston O-Rings
309457E 49
Repair
Adjust the Actuator Arm
The fluid nozzle (4) must be in place when removing or installing the jam nut and actuator arm.
1.
Install the adjustment nut (30), actuator arm (29), and jam nut (28) onto the piston rod (34b). Note that the jam nut (28) has a slightly larger hex and a thin-
ner profile than the adjustment nut (30). See F IG .
2.
Position the parts so there is a 0.125 in. (3 mm) gap between the actuator arm (29) and the fluid packing rod nut (E), which allows the atomizing air to actuate
before the fluid. See F IG . 29..
3.
Tighten the adjustment nut (30) against the actuator arm (29). Check that the 0.125 in. (3 mm) gap has been maintained. In addition, there should be 3-4 mm of electrode needle travel when the gun is triggered. Adjust the jam nut position to obtain these dimensions.
4.
5.
Install the gun shroud (2) and air cap (3), page 45.
6.
Install the gun onto the manifold and bracket. See
29
28
0.125 in. (3 mm) gap
30 34b
Fig. 29. Actuator Arm Adjustment
E
TI1567A
50 309457E
Repair
Barrel Removal
1.
Prepare the gun for service, page 43.
2.
Remove the air cap, page 45. Remove the gun
shroud (2).
3.
Carefully loosen the fluid fitting nut (20). Pull the tube (19) out of the fitting (23). Make sure both ferrules (21, 22) and the nut stay with the tube.
4.
Remove the jam nut (28) and actuator arm (29). See
5.
Loosen the three screws (10, 33). See F IG . 30..
6.
Hold the gun body (32) with one hand and pull the
barrel (9) straight off the body. See F IG . 30..
9
10
32
33
CAUTION
To avoid damaging the power supply (12), pull the gun barrel (9) straight away from the gun body (32). If necessary, gently move the gun barrel from side to side to free it from the gun body.
Fig. 30. Barrel Removal
32
9
TI1781A
29
28 30 19
TI1800A
Fig. 31. Disconnect Fluid Tube
309457E 51
Repair
Barrel Installation
1.
Be sure the gasket (11) and grounding spring (51) are in place. Make sure the air holes are aligned
properly. Replace if damaged. See F IG . 32..
2.
Place the barrel (9) over the power supply (12) and onto the gun body (32).
3.
Tighten the three screws (10, 33) oppositely and evenly (about a half turn past snug).
4.
Assemble the fluid tube (19) into the fluid fitting (23).
Ensure that the ferrules (21, 22) are in place.
Tighten the nut (20).
5.
Install and adjust the actuator arm (29) and jam nut
6.
7.
Install the gun shroud (2) and air cap, page 45.
8.
Install the gun onto the manifold and bracket. See
CAUTION
Do not over-tighten the screws (10, 33).
32
10
11
12
33
TI1785A
9
51 28
29
Fig. 32. Barrel Installation
52 309457E
Repair
Power Supply Removal and
Replacement
• Inspect the gun body power supply cavity for dirt or moisture. Clean with a clean, dry rag.
• Do not expose gasket (11) to solvents.
1.
Prepare gun for service, page 43.
2.
Remove the barrel (9), page 51.
CAUTION
Be careful when handling the power supply (12) to avoid damaging it.
3.
Grasp the power supply (12) with your hand. With a gentle side to side motion, free the power supply/alternator assembly from the gun body (32), then carefully pull it straight out. Disconnect the flexible circuit (39) from the socket at the top of the body
(32). See F IG . 33., page 54.
4.
Disconnect the 3-wire connector (GG) from the power supply. Slide the alternator up and off the power supply. Inspect the power supply and alternator for damage. Disconnect the 6-pin flexible circuit
(39) from the power supply.
5.
Check the power supply resistance, page 35.
Replace if necessary.
Before installing the power supply, make sure the o-rings (12a, 13a), spring (12b), and pads (13e) are in place.
6.
Connect the 6-pin flexible circuit (39) to the power supply.
7.
Connect the 3-wire connector (GG). Slide the alternator (13) down onto the power supply (12).
8.
Lubricate the alternator o-ring (13a) with non-silicone grease, Part No. 111265. Do not over-lubricate.
9.
Lubricate the power supply o-ring (12a) with dielectric grease.
10. Insert the power supply/alternator assembly in the gun body (32). Make sure the ground strips make contact with the body. Connect the flexible circuit
(39) to the socket at the top of the body. Push the
6-pin connector into the socket to ensure it is properly connected.
11. Install the barrel (9), page 52.
12. Test gun resistance, page 34.
309457E 53
Repair
12
39
11
12a
12b
32
GG
13e
13
13a
TI1784A
Fig. 33. Power Supply
Turbine Alternator Removal and Replacement
Replace turbine alternator bearings after 2000 hours of operation. Order Part No. 223688 Bearing Kit.
1.
Prepare gun for service, page 43.
2.
Remove the power supply/alternator assembly,
3.
Disconnect the alternator from the power supply,
4.
Measure resistance between the two outer terminals of the 3-wire connector (GG); it should be
2.5-3.5 ohms. If outside this range, replace the alternator coil.
5.
Follow the bearing replacement procedure in the bearing kit manual 308034.
6.
Install the alternator on the power supply, page 53.
7.
Install the power supply/alternator assembly, page
54 309457E
Parts
Parts
Part No. 244591 PRO Auto Xs Electrostatic Gun, Series A, for waterborne coatings
7
2
4
4a
4b
3
8
1
1a
39
13
13a
Ref. No. 13: Alternator Detail
13b
13a
9
10
11
12a
12b
12
35
13e
41
13b
TI1481a
26
27
28
29
30
25
51
13e
34e
34f
34c
34d
34a 40
13d 13c
33
34g
32
34b
8a
TI1777A
8f
8c
8d
8g
8b
8e
8h ti1601a
Ref. No. 8: Packing Rod Detail
31
309457E 55
Parts
Part No. 244591 PRO Auto Xs Electrostatic Gun, Series A, for waterborne coatings
8c*
8d*
8e
8f
7
8
8a*
8b*
8g*
8h
9
10
276867
244521
111316
116905
178409
178763
197641
185495
186069
244696
244394
197518
1a*†
2
3
4
4a
4b
5
Ref.
No.
1
Part No.
Description
244950
11*†
198307
245325
197477
197266
111261
111507
198486
197517
Qty
RING, retaining, air cap; includes
1a
1
. U-CUP 1
SHROUD
AIR CAP
NOZZLE; 1.5 mm orifice; includes
4a and 4b
1
1
1
. O-RING, conductive
. O-RING; fluoroelastomer
CONNECTOR, tube, fiber optic;
NEEDLE, electrode, WB
ROD, packing; includes 8a-8h
. O-RING; fluoroelastomer
. SEAL
. SPREADER, packing; uhmwpe 1
. PACKING, rod; acetal 1
. NUT, packing
. HOUSING, packing
1
1
1
1
1
1
1
1
1
. SPACER, packing; acetal
. ROD, packing
BARREL, gun
SCREW; socket-hd; 10-24 x 3/4 in. (19 mm)
GASKET, barrel
1
1
1
1
1
Ref.
No.
Part No.
Description Qty
12
12a*†
12b
13
13a*†
13b
16
17
27
28
29
30
31
19
25
26
13c
13d
13e
15
244542
103337
197624
244555
110073
223688
244577
111745
198821
107460
179791
186118
197624
185111
189367
185122
101324
197919
102025
112689
POWER SUPPLY, 60 kV; includes
12a-12b
1
. O-RING; fluoroelastomer 1
. SPRING, compression
TURBINE, alternator; includes
13a-13e
. O-RING; fluoroelastomer
1
1
1
1 . BEARING KIT; includes front and rear bearings and fan
. COIL
. RING, retaining
2
1
1
1
. PAD, pressure
TOOL, wrench, ball end
(not shown)
TAG, warning (not shown); replacement available at no cost
SIGN, warning (not shown); replacement available at no cost
SPRING, grounding
1
1
SPRING, compression
CAP, exhaust
MUFFLER
NUT, jam, hex
1
1
1
ARM, actuator
NUT, hex
SCREW, button-hd; 1/4-20 x 3/4 in. (19 mm)
1
1
1
1
1
32
33
198363
116575
BODY, gun, auto, WB 1
SCREW, cap, socket-hd; 10-24; 3 in. (76 mm)
2
56 309457E
Parts
Ref.
No.
Part No.
Description
34
34a
34b
244702
197920
189754
34c 189355
34d*† 189752
34e*† 111504
34f*† 112319
34g*† 111508
35 244938
37 245265
PISTON; includes 34a-34g
. PISTON
. ROD, piston
. STEM, piston
. PACKING, u-cup
. O-RING
. O-RING
. O-RING
MANIFOLD; see separate parts
CIRCUIT, flexible
Qty
2
2
2
1
1
1
1
1
1
1
Ref.
No.
Part No.
Description
39
40
42
48
276741
189888
116553
290171
MULTI-TOOL
COVER, gun; box of 10 (not shown)
TUBE, grease, lubricant
SIGN, warning (not shown); replacement available at no cost
Qty
1
1
1
* Recommended spare parts. Keep on hand to reduce downtime.
† Included in repair kit 15D592.
Replacement Warning labels, signs, tags, and cards are available at no cost.
309457E 57
Parts
Part No. 244938 Manifold, Series A
101 (Ref) 106 (Ref)
112
113 105
116
116a
119
114
109
117 120
115
102
TI1796A
104
103
108
106
101
TI1791A
Ref.
No.
Part No.
Description
107
108
109
110
101
102
103
104
105
106
198362
189581
110465
112689
112640
197518
111157
186845
110078
112646
MANIFOLD
BRACKET, reciprocator
SCREW, set
SCREW, button-hd
SPRING, compression
SCREW; socket-hd; 10-24 x 3/4 in. (19 mm)
FITTING, tube
FITTING, turbine
FITTING, tube, fluid
PLUG
Qty
2
1
1
1
2
1
3
1
1
2
107
Ref.
No.
Part No.
Description
112† 197925
113 108290
114 189365
115 198764
116 244772
116a† 112085
117 114263
119 116621
120 112645
GASKET, manifold
SCREW, machine
CAP, kV, HI/LO
RESTRICTOR
PISTON; includes 116a
. O-RING
FITTING, connector
SPRING, compression
PLUG
† Included in repair kit 15D592.
110
Qty
3
2
2
1
1
2
1
1
2
58 309457E
Accessories
Accessories
Air Line Accessories
Grounded Air Hose (Red Cover)
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
0.315 in. (8 mm) ID; 1/4 npsm(f) x 1/4 npsm(f) left-hand thread; red cover with stainless steel braid ground path.
235068
235069
235070
235071
6 ft (1.8 m)
15 ft (4.6 m)
25 ft (7.6 m)
36 ft (11 m)
235072
235073
50 ft (15 m)
75 ft (23 m)
235074 100 ft (30.5 m)
Bleed-Type Master Air Valve
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
Relieves air trapped in the air line between this valve and the pump air motor when closed.
107141 3/4 npt
Air Line Shutoff Valve
150 psi (10 bar, 1.0 MPa) Maximum Working Pressure
For turning air to gun on or off.
224754 1/4 npsm(m) x 1/4 npsm(f) left-hand thread.
Fluid Line Accessories
Shielded Waterborne Fluid Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
PTFE; 1/4 in. (6 mm) ID
245327
245328
25 ft (7.6 m)
36 ft (11 m)
Unshielded Waterborne Fluid Hose
100 psi (7 bar, 0.7 MPa) Maximum Working Pressure
PTFE; 1/4 in. (6 mm) ID. See manual 308688 for installation requirements.
245329
245330
25 ft (7.6 m)
36 ft (11 m)
Fluid Shutoff/Drain Valve
500 psi (35 bar, 3.5 MPa) Maximum Working Pressure
For turning fluid on or off to the gun and for relieving fluid line pressure at the pump.
208630
Drain Valve
1/2 npt(m) x 3/8 npt(f); carbon steel and
PTFE; for non-corrosive fluids
300 psi (21 bar, 2.1 MPa) Maximum Working Pressure
236853 Mounts directly to gun manifold for faster flushing and color changes. Must be used with 233676 Fluid Recirculation Kit.
309457E 59
Accessories
Miscellaneous Accessories
Ground Wire and Clamp
222011 For grounding pump and other components and equipment in the spray area.
12 gauge, 25 ft (7.6 m).
Megohmmeter
241079 500 Volt output; 0.01-2000 megohms.
Not for use in hazardous areas.
Grounding Rod
210084 Use to discharge voltage from voltage isolation system enclosure.
Safety Warning Signs
180060 English Warning Sign. FM Approved. Available at no charge from Graco.
ES Display Module
224117 Receives fiber optic transmission from the
PRO Auto Xs gun and displays the gun’s output voltage and current. Mounts in a standard 19 in. DIN rack. See 308265.
Power Supply
235301 Supplies low voltage DC power to 224117
Display Module. See 308265.
Fiber Optic Y Cables
See item T in F IG . 3. on page 12. For use with 224117
Display Module only. Connect gun manifold and display module, or bulkhead connector and display module. See
308265.
224682
224684
25 ft (7.6 m)
50 ft (15 m)
224686 100 ft (30.5 m)
Remote Voltage Display
189762 Battery-operated meter displays actual spraying voltage. remote mount outside hazardous area. Connects to gun via fiber optic cable. See 308265.
Remote Voltage Display Kits
Include 189762 Remote Voltage Display and fiber optic cable.
236917
236919
25 ft (7.6 m)
50 ft (15 m)
236921 100 ft (30.5 m)
Fiber Optic Cables
See item V in F IG . 3. on page 12. Connect gun manifold and remote voltage display, bulkhead connector and remote display, or bulkhead connector and gun manifold. See 308265.
224672
224674
25 ft (7.6 m)
50 ft (15 m)
224676 100 ft (30.5 m)
Bulkhead Connector
189870 For connecting two fiber optic cables.
60 309457E
Accessories
Gun Accessories
Round Pattern Kits
Consists of fluid tip, diffuser and air cap.
245217
245219
4-6 in. (102-152 mm) diameter
8-10 in. (203-254 mm) diameter
Dielectric Grease
116553 1 oz (28 g) tube of dielectric grease for the power supply o-ring (12a), some packing rod parts (8), and certain fluid fittings.
Gun Valve Lubricant
111265 4 oz (113 g) tube of sanitary (non-silicone) lubricant for fluid seals and wear areas.
Alternator Bearing Kit
223688 To repair the turbine alternator.
Cleaning Brush
105749 For cleaning air cap and fluid nozzle.
309457E 61
Technical Data
Technical Data
Category
Maximum Working Fluid Pressure
Maximum Working Air Pressure
Minimum Air Pressure at Gun Inlet
Maximum Fluid Operating Temperature
Short Circuit Current Output
Voltage Output
Sound Power (measured per ISO Standard 9216)
Sound Pressure (measured 1 m from gun)
Turbine air inlet fitting, left-hand thread
Atomizing air inlet fitting
Fan air inlet fitting
Cylinder air inlet fitting
Hi/Lo voltage selector air inlet fittings
Fluid inlet fitting
Gun Weight
Gun Length
Wetted Parts
Data
100 psi (0.7 MPa, 7 bar)
100 psi (0.7 MPa, 7 bar)
40 psi (0.28 MPa, 2.8 bar)
120
°
F (48
°
C)
125 microamperes
30-60 kV at 40 psi (0.28 MPa, 2.8 bar): 90.4 dB(A) at 100 psi (0.7 MPa, 7 bar): 105.4 dB(A) at 40 psi (0.28 MPa, 2.8 bar): 87 dB(A) at 100 psi (0.7 MPa, 7 bar): 99 dB(A)
1/4 npsm(m)
3/8 in. OD nylon tube
3/8 in. OD nylon tube
5/32 in. OD nylon tube
5/32 in. OD nylon tube custom
3.52 lb (1.6 kg)
12.25 in. (31.1 cm)
Stainless Steel; Nylon, Acetal, Ultra-High Molecular
Weight Polyethylene, Fluoroelastomer, PEEK, Tungsten
Wire, Polyethylene
Loctite® is a registered trademark of the Loctite Corporation.
62 309457E
Technical Data
309457E 63
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by
Graco, Graco will, for a period of twelve months or two thousand hours of operation from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. However, any deficiency in the gun barrel, gun body, manifold, mounting bracket, internal power supply, and alternator (excluding turbine bearings) will be repaired or replaced for thirty-six months or six thousand hours of operation from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco's written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by
Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts.
The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco's sole obligation and buyer's sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
Graco Information
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1-800-367-4023 Toll Free
612-623-6921
612-378-3505 Fax
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
This manual contains English. MM 309457
Sales Office: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441 www.graco.com
309457 Revised 10/2007
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